Engine Cooling System: Radiator: Reassembly

1. Clean the O-rings contact surface of the lower tank and oil cooler.
   Fig 1: Installing Oil Cooler To Lower Tank

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2. Install 2 new O-rings to the oil cooler.
3. Install the oil cooler to the lower tank.
4. Install the plate washer and nut.

   Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

5. Install the cooler pipe.

   Torque: 15 N*m (150 kgf*cm, 11 ft.*lbf) 

6. Install the screw.

1. After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.

   HINT:

   When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

   Fig 2: Installing O-Ring Without Twisted

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2. Install the tank without damaging the O-ring.
3. Tap the lock plate with a soft-faced hammer so that there is no gap between the lock plate and the tank.

SST 09230-01010, 09231-14010 

Fig 3: Tapping Lock Plate With Soft-Faced Hammer

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1. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in Fig 4.
   Fig 4: Installing Punch Assembly To Overhaul Handle

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2. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in Fig 4.

   Dimension B: 

   8.4 mm (0.331 in.) 

1. Lightly press SST against the lock plate in the order shown in Fig 5. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.
   Fig 5: Identifying Caulk Lock Plate

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   SST 09230-01010 

   HINT:

   • Do not tap the areas protruding around the pipes, brackets or tank ribs.
   • The dotted circles shown in the illustration and parts of the oil cooler near the dotted circles cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.
2. Check the lock plate height (H) after completing the caulking.
   Fig 6: Measuring Plate Height

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   Plate height (H): 

   7.40 to 7.80 mm (0.2913 to 0.3071 in.) 

   If not within the specified height, adjust the stopper bolt of the handle and caulk again.

1. Install a new O-ring to the drain plug.
2. Install the drain plug.

1. Plug the inlet and outlet pipes of the radiator with SST.
   Fig 7: Plugging Inlet And Outlet Pipes Of The Radiator With SST

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   SST 09230-01010 

2. Using a radiator cap tester, apply pressure to the radiator.

   Test pressure: 

   177 kPa (1.8 kgf/cm ²  , 26 psi) 

3. Submerge the radiator in water.
4. Inspect for leaks.

   HINT:

   On radiators with resin tanks, there is clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.

   Fig 8: Identifying Lock Plate And O-Ring

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